Integrated circuit on flexible substrate manufacturing process

ABSTRACT

The present invention provides processes for manufacturing a plurality of discrete integrated circuits (ICs) on a carrier, the process comprising the steps of: providing a carrier for a flexible substrate; depositing a flexible substrate of uniform thickness on said carrier; removing at least a portion of the thickness of the flexible substrate from at least a portion of the IC connecting areas to form channels in the flexible substrate and a plurality of IC substrate units spaced apart from one another on the carrier by said channels; forming an integrated circuit on at least one of the IC substrate units.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a national stage application under 35 U.S.C. 371 ofPCT Application No. PCT/GB2019/050243, having an international filingdate of Jan. 30, 2019, which designated the United States, which PCTapplication claimed the benefit of Great Britain Application No.1801457.1, filed Jan. 30, 2018, each of which are incorporated herein byreference in their entirety.

FIELD

This invention relates to a process and apparatus for manufacturingintegrated circuits (ICs) and to a carrier comprising a plurality ofintegrated circuits. In particular, the invention relates to a processand apparatus for manufacturing a plurality of discrete ICs on aflexible substrate and to a carrier comprising a plurality of discreteintegrated circuits on a flexible substrate.

BACKGROUND

Current wafer processing techniques involve placing a wafer, typicallyof crystallised silicon and comprising a plurality of integratedcircuits (ICs) thereon, on an adhesive film on a large wafer frame. Thewafer is diced before being placed into an integration machine undertension to create spaces between adjacent dies, each of the diescomprising an IC. During handling of the resulting integrated circuit(IC), a single die may then be picked up or displaced from the adhesivefilm and either placed directly onto a first support havingcorresponding contact pads during the formation of an electroniccircuit, or if orientation flipping is required placed onto a secondpick tool before placement onto the said support having correspondingcontact pads.

In processes using a flexible plastic substrate as opposed to a siliconwafer, the same process can be accomplished, with an additional step ofa release process from an initial carrier (e.g. glass, polycarbonate orquartz), supporting the flexible plastic substrate, prior to thetransfer of the plastic substrate to a transfer means in an integrationapparatus. This process of removal from the glass carrier results in anarray of diced flexible ICs in a format that has sufficient adhesion forshipment and handling on the glass carrier, whilst also allowing for avacuum head to remove individual flexible ICs from the glass carrierduring subsequent handling.

Release processes for a flexible plastic substrate, on which theelectronics (e.g. integrated circuits) are laid, from the carrier (e.g.glass, polycarbonate or quartz) typically involve treatment from thebackside of the carrier with an electromagnetic radiation source (e.g. alaser, flashlamp, high powered LED, an infrared radiation source or thelike). The mechanism will depend on whether the electromagneticradiation source causes predominantly a photonic ablation (throughabsorption) or a thermal process (e.g. heat-release). Optionally anadhesive/release material can be employed between the carrier and theflexible plastic substrate. The laser is scanned at fixed, discreteintervals across the surface. The laser modifies the interface betweenthe flexible plastic substrate (e.g. a film) and the glass carrier,either by local ablation of a thin layer of substrate, or by reducingbond strength. Control of the laser to achieve this balanced release ina uniform manner has proven difficult with a narrow process window.

In conventional processes, singulating the ICs on a substrate (wafer),flexible or rigid, is performed by ‘dicing’, that is cutting thesubstrate along straight lines between the ICs after they are formed ina process known as ‘back end processing’ and, if the wafer is flexible,subsequently releasing the discrete ICs to form singulated ICs. Whendicing flexible substrates this conventional approach is often performedby a laser or abrasive water jet. Such processes are time-consuming andproduce ‘dirty’ waste material that must be removed from the completedsubstrate (wafer). Furthermore, the processes may generate significantlocal heating of the substrate and may produce poor edge quality aroundeach singulated IC. In addition, the scribe line width formed betweeneach of the discrete ICs in the dicing process may be at least 10 μmwhich width is a waste of valuable substrate.

BRIEF SUMMARY OF THE DISCLOSURE

Accordingly, it is an object of certain embodiments of the invention toprovide a process and apparatus for manufacturing a plurality ofintegrated circuits which overcome, at least partly, one or more of theproblems associated with the prior art.

Aspects and embodiments of the invention provide a process formanufacturing a plurality of discrete integrated circuits, apparatus formanufacturing a plurality of discrete integrated circuits and a carriercomprising a plurality of discrete integrated circuits on a flexiblesubstrate as claimed in the appended claims.

According to a first aspect of the invention there is provided a processfor manufacturing a plurality of discrete integrated circuits (ICs) on acarrier, the process comprising the steps of:

-   -   providing a carrier for a flexible substrate;    -   depositing a flexible substrate of uniform thickness on said        carrier;    -   patterning said uniform thickness flexible substrate to define a        plurality of IC substrate areas spaced apart from one another by        a plurality of IC connecting areas;    -   removing at least a portion of the thickness of the flexible        substrate from at least a portion of the IC connecting areas to        form channels in the flexible substrate and a plurality of IC        substrate units spaced apart from one another on the carrier by        said channels;    -   forming an integrated circuit on at least one of the IC        substrate units.

According to a second aspect of the invention there is provided aprocess for manufacturing a plurality of discrete integrated circuits(ICs) on a carrier, the process comprising the steps of:

-   -   providing a carrier for a flexible substrate;    -   depositing a flexible substrate of uniform thickness on said        carrier;    -   patterning said uniform thickness flexible substrate to define a        plurality of IC substrate areas spaced apart from one another by        IC connecting areas;    -   forming a portion of an integrated circuit on at least one of        the IC substrate areas;    -   removing at least a portion of the thickness of the flexible        substrate from at least a portion of the IC connecting areas to        form channels in the flexible substrate and a plurality of IC        substrate units spaced apart from one another on the carrier by        said channels; and    -   completing the formation of the integrated circuit on the at        least one of the IC substrate areas.

Unless otherwise stated, the following embodiments are embodiments ofboth the first aspect and the second aspect of the invention.

In certain embodiments the process comprises the step of pre-treatingthe carrier (or other layer beneath the substrate) to prevent theflexible substrate from adhering to the carrier in the IC connectingareas. More specifically, the carrier (or other layer beneath thesubstrate) may be subjected to a plasma treatment in the areas that willbecome the IC connecting areas. In certain embodiments a material may bedeposited in the areas that will become the IC connecting areas. Incertain embodiments a material is deposited on the carrier (or otherlayer beneath the substrate) in a pattern in the areas that will becomethe IC connecting areas. In this way the carrier (or other layer beneaththe substrate) can be pre-treated to prevent the flexible substrate fromadhering to the carrier (or other layer beneath the substrate) in thosepre-treated areas. The pre-treatment occurs before deposition of thesubstrate on the carrier (or other layer beneath the substrate).

In certain embodiments the steps of depositing a flexible substrate ofuniform thickness on said carrier and patterning said uniform thicknessflexible substrate to define a plurality of IC substrate areas spacedapart from one another by a plurality of IC connecting areas are asingle step comprising selective deposition of a pattern of flexiblesubstrate of uniform thickness on said carrier.

In certain embodiments, the flexible substrate is between about 0.5 μmand about 20 μm thick when deposited. More specifically, the flexiblesubstrate is between about 1 μm and about 10 μm. In certain embodimentsthe flexible substrate is about 5 μm thickness when deposited.

In certain embodiments the process comprises forming integrated circuitson each of the IC substrate units.

In certain embodiments each IC substrate unit comprises flexiblesubstrate of uniform thickness.

In certain embodiments the process comprises the step of removing theentire thickness of the flexible substrate from all of each of the ICconnecting areas so as to form a plurality of substrate-free channels onthe carrier between each adjacent IC substrate unit on the carrier.

In certain embodiments the process comprises removing the entirethickness of the flexible substrate from a portion of each of the ICconnecting areas so as to form a plurality of patterned channels on thecarrier wherein at least one channel is formed between each of the ICsubstrate units.

In certain embodiments the process comprises removing a portion of thethickness of the flexible substrate from each of the IC connecting areasso as to form a plurality of channels on the carrier, wherein eachchannel comprises interconnecting portions of substrate between adjacentIC substrate units.

In certain embodiments the flexible substrate interconnecting portionsconnecting adjacent IC substrate units in the channels are about 100 nmto about 200 nm thick, and the IC substrate units are between about 0.5μm and about 20 μm thick. More specifically, the flexible IC substrateunits are each between about 1 μm and about 10 μm thick. In certainembodiments the flexible IC substrate units are each about 5 μmthickness when deposited. In this way, the substrate interconnectingportions form a bridge between adjacent IC substrate units. This has theadvantage that when the substrate is released from the carrier, the ICsubstrate units remain connected by the interconnecting portions untilsuch time as IC integration is initiated.

In certain embodiments the process comprises removing a first portion ofthe thickness of the flexible substrate from a first portion of each ofthe IC connecting areas and removing a second portion of the thicknessof the flexible substrate from a second portion of each of the ICconnecting areas.

In certain embodiments the first portion is of greater thickness thanthe second portion.

In certain embodiments the process comprises forming perforation linesbetween adjacent IC substrate units in the IC connecting areas bysequentially removing and leaving the entire thickness of the flexiblesubstrate along each of the IC connecting areas so as to form aplurality of patterned channels on the carrier wherein at least onechannel is formed between each of the IC substrate units.

In certain embodiments the process comprises forming perforation linesbetween adjacent IC substrate units in the IC connecting areas bysequentially removing a first portion of the thickness of the flexiblesubstrate from a first portion of each of the IC connecting areas andremoving a second portion of the thickness of the flexible substratefrom a second, different portion of each of the IC connecting areas,wherein the first portion is of greater thickness than the secondportion.

In certain embodiments the process comprises forming perforation linesbetween adjacent IC substrate units in the IC connecting areas bysequentially removing the entire thickness of the flexible substrate anda partial thickness of the flexible substrate along each of the ICconnecting areas so as to form a plurality of patterned channels on thecarrier wherein at least one channel is formed between each of the ICsubstrate units.

In certain embodiments the process comprises forming at least onestructure in an IC connecting area by removing the entire thickness ofthe flexible substrate from a portion of the IC connecting area so as toform a channel having at least one structure of flexible substrate inthe channel, the structure being spaced apart from the IC substrateunits adjacent to the channel.

In certain embodiments the structure is a test structure. In this way,the pattern alignment and/or etching for the substrate and/or one ormore layers of the IC during formation thereof can be tested andverified to ensure each layer is patterned and formed in alignment withpreviously deposited layers. In certain embodiments test structures canbe used to gather information about any desired aspect of the process,devices and/or circuits.

In certain embodiments the process comprises depositing a filler in thechannels, the channels being either substrate-free or patterned.

In certain embodiments the filler is removably deposited in the channels(e.g. substrate free or patterned).

In certain embodiments, the filler is deposited in the channels (e.g.substrate free or patterned) so as to fill the channels. In this way,the channels are filled completely to the level of the upper surface ofthe IC substrate units such that the IC substrate units (or the ICformed thereon) and the upper surface of the filler in the channels aresubstantially co-planar. In this way, subsequent processing during ICmanufacture may be improved (e.g. made easier).

Thus, the channels or ‘lanes’ between the patterned IC substrate units(that subsequently have ICs deposited upon them) may be patterned, andoptionally removed, repeatedly during IC formation as layers aredeposited. In an alternative approach, following initial patterning ofthe substrate and formation of the IC substrate units, the channelsbetween IC substrate units may be filled with a material that may beeasily removed, for example, at the IC singulation stage. This approachis applicable to processes in which the channels between IC substrateunits are completely removed and to those in which the substrate is onlypartially removed from the IC connecting areas, e.g. leaving behind somesubstrate connecting adjacent IC substrate units.

In certain embodiments, upon completion of the formation of anintegrated circuit the material used to fill the channels and any layersdeposited on top of them may be removed by chemical processing, e.g. wetor dry etching.

In certain embodiments, the IC substrate units are formed by patterningthe flexible substrate by photolithography or selective deposition.

In certain embodiments, the filler deposited in the channels between ICsubstrate units is a metal. More specifically, the metal filler is oneor more of: nickel, copper, silver, gold and palladium.

In certain embodiments, the filler is applied by electroless plating,e.g. of nickel, copper, silver, gold, palladium or any suitablealternative. This enables the wafer comprising the flexible substrateand filler to be substantially planarized. In this way, any deleteriouseffects arising in subsequent deposition and etching steps in ICmanufacture may be reduced. Once IC manufacturing is complete, the ICsmay be singulated on the carrier (e.g. glass) using an appropriatechemical process, such as wet or dry etching, to selectively detach thechannel fillings (e.g. metal) and the layers deposited onto them. Manysuitable chemical processes are known in the art, for example there areselective etchants for copper and nickel that would not etch aluminium.

In certain embodiments, the bottom of the channel is cleared of fillerif the aspect ratio of the channel is not too high, and the channel isnot too narrow. More specifically, the bottom of the channel is clearedof filler when the channel is greater than about 1 micron width.

In certain embodiments, a mask protecting the integrated circuit of theat least one IC substrate unit is provided. This is advantageous in adry-etch process for example.

In certain embodiments, the filler is a polymer. More specifically, thepolymer filler differs from the polymer of the flexible substrate.

In certain embodiments, the flexible substrate is formed from one of:PEN (polyethylene naphthalate) and PI (polyimide). In these embodiments,the channels may be filled with a different polymer, being one of: PMMA(polymethyl methacrylate) and PVA (polyvinyl acetate).

In certain embodiments, after integrated circuits are formed on the ICsubstrate units, the IC substrate units may be singulated by using asuitable process, for example a solvent process or a wet or dry etchingprocess, to selectively remove the channel-filling polymer. In certainembodiments, depending on the processes used to form integrated circuitson the IC substrate units, it may be necessary to protect thechannel-filling polymer with a capping layer to prevent its removalduring integrated circuit formation. Any such capping layer may bepatterned to align with only the channels between IC substrate units, orit may additionally substantially cover the upper surfaces of the ICsubstrate units. In certain embodiments, the capping layer may beremoved from the channel-filling polymer at an appropriate point priorto integrated circuit singulation.

In certain embodiments, prior to, or after, depositing the flexiblesubstrate onto the carrier, the process may comprise the step ofapplying a metal seeding layer.

In certain embodiments the metal seeding layer is applied using anysuitable deposition technique. In certain embodiments, the metal seedinglayer is applied using sputtering. It should be understood that anyother appropriate patterning and deposition techniques may be used toapply the metal seeding layer.

In certain embodiments the metal seeding layer is patterned usinglithography or etching.

In certain embodiments the metal seeding layer is applied in a pattern.More specifically, the metal seeding layer is applied in a pattern whichwill match, or substantially match, the pattern of the IC connectingareas. In this way, the channels formed by complete removal of thesubstrate in the IC connecting areas will expose the metal seedinglayer. Alternatively, the metal seeding layer is applied in a pattern inthe channels between the IC substrate units. More specifically, themetal seeding layer is applied after the deposition of the flexiblesubstrate and the formation of the channels in the substrate.

Thus, once the pattern of the metal seeding layer is applied, theflexible substrate is deposited, if not done previously, and patternedso as to form the channels, that is to say either the channels areetched in a flexible substrate layer deposited over the metal seedinglayer, or flexible substrate is selectively deposited between the metalseeding channels.

After the IC substrate units have been formed by patterning the flexiblesubstrate and removing the channels, a further (thicker) layer of metalis grown on the metal seeding layer to fill the channels between ICsubstrate units. This may be performed by any suitable known technique,such as chemical vapour deposition, physical vapour deposition,electroplating, electroless plating, or the like.

In certain embodiments, through-chip vias and/or bottom-side integratedcircuit contact pads may be formed. More specifically, initialpatterning of the metal layer may include applying metal layer or metalseeding layer features within the boundaries of subsequently formed ICsubstrate units, either in addition to or instead of any such patterningin the channels between IC substrate units.

Alternatively, in certain embodiments the metal layer, e.g. metalseeding layer or other metal layer deposited by electroplating, vapourdeposition, etc., may be applied after the IC substrate units and theirinternal features (e.g. internal vias) have been formed. Morespecifically, internal features of the IC substrate units may be formedand filled in addition to, or instead of, the channel features aspreviously described in relation to metal seeding and/or metal fillingsteps. If metal seeding is performed, once the flexible substrate andmetal seeding layers have been patterned a thicker layer of metal isgrown on the metal seeding layer to substantially fill the internalfeatures of the IC substrate units.

In certain embodiments, the metal layer may be grown or deposited up tothe upper surface of the IC substrate units.

In certain embodiments, during the subsequent process of IC formation onthe IC substrate units, IC wiring (e.g. metal tracks) may be connectedto the metal deposited onto the internal features. Following completion(which may include deposition of further layers) and singulation of theIC and its separation from the carrier, the internal features formcontact pads on the underside of the IC (bottom-side contacts'). Thecontact pads may be connected to application circuits, e.g. antennas,without inverting the IC, which simplifies the assembly process.

By building up further layers of metal on top of the metal-filledinternal features, it is possible to produce ‘through-chip vias’, that,is conductive features running between the upper surface of the IC andthe lower surface of the IC. This allows for “stacking” of ICs and/orother components in the same physical area, or overlapping areas, on theapplication substrate. This can save area and reduce metal tracking ofinterconnects, reducing cost of the application circuit by either simplyreducing area and tracking, or also in some cases by eliminating theneed for “crossovers” in metal tracking on the application circuit,reducing the number of required fabrication steps.

In certain embodiments, contact pads can be produced by applying a metallayer to the carrier prior to depositing the flexible substrate.Alternatively, in certain embodiments, contact pads can be produced bydepositing flexible substrate first then the metal layer.

In certain embodiments, metal contact pads are patterned directly on thecarrier (e.g. glass) by applying the metal layer in a discrete patternon the carrier. The flexible substrate is subsequently deposited ontothe metal layer.

In certain embodiments, vias are then etched through the flexiblesubstrate layer (e.g. with an oxygen plasma dry etch for polyimidefilms), and connections made to the upper layers. In certainembodiments, these connections are made by applying an upper metal layerto the flexible substrate. In such embodiments, the upper metal layerroutes over positively sloped sidewalls around the etched vias to formconnections, or fills the vias (using methods such aselectro/electro-less plating techniques). In this method, the vias inthe flexible substrate connecting to the bottom pad could consist of alimited area, with the pad extending beyond them.

In certain embodiments, a flexible substrate (e.g. plastic film) isdeposited on the carrier (e.g. glass), followed by the etching of thevias through the flexible substrate. In certain embodiments, the via isnarrower at the bottom than at the top (i.e. the via walls areconverging towards the bottom). Subsequently, a metal layer isdeposited, allowing for no breakages at the via edges, thus routing themetal both down to contact the carrier, and up to the top of thesubstrate layer. The bottom contact pad area is defined in this methodby the size of the via, leading to large etched regions of the flexiblesubstrate. In other words, deposition of a metal contact pad prior todeposition of the IC substrate unit optionally allows that contact padto be larger in area than an internal feature (e.g. an internal via)subsequently formed above it and filled with metal to connect to it. Incontrast, bottom side contacts formed only after deposition of the ICsubstrate unit may be limited in area to that of the internal feature.

In certain embodiments, in order to ensure proper release of the metalcontact pad areas from the carrier, a release layer may be appliedunderneath the metal contact pad. The release layer is designed tointeract with a laser used for release and to result in complete releaseof the metal contact pad area from the carrier.

In certain embodiments, the release layer comprises a titaniuminterfacial layer under an aluminium contact pad.

In certain embodiments the IC substrate units on the carrier are uniformin shape. More specifically the IC substrate units are polygonal. Inthis way, a large number of IC substrate units can be formed on thecarrier without large areas of wasted substrate.

Alternatively, the IC substrate units are irregular in shape. In thisway, the shape of the IC substrate units and the ICs formed thereon mayform a security and traceability feature of the product.

In certain embodiments at least one edge of at least one of the ICsubstrate units on the carrier comprises at least one indentation.

In certain embodiments the edge comprises a series of indentations. Inthis way, the edge profiling of a least one IC substrate unit providesan identification code by which a carrier and, more particularly thesubstrate and the ICs formed thereon can be tracked through themanufacturing process and beyond.

In certain embodiments the carrier is rigid. More specifically thecarrier is glass, polycarbonate or quartz.

In certain embodiments the carrier is flexible. More specifically thecarrier is a flexible release tape.

In certain embodiments at least a portion of the flexible substrate isremoved from the IC connecting areas to form channels in a pattern atpredetermined location(s) on the carrier.

In certain embodiments the pattern is formed of a series of intersectingchannels extending between the edges of the carrier.

In certain embodiments the pattern of channels is uniform across thecarrier.

In certain embodiments the pattern of channels is non-uniform across thecarrier.

In certain embodiments the flexible substrate is formed of a singlelayer.

In certain embodiments the flexible substrate material is a polymer.

In certain embodiments the flexible substrate material comprises one ormore of polyimide, polyethylene terephthalate (PET), parylene,benzocyclobutene, amorphous fluoropolymer e.g. Cytop™ (AGC ChemicalsEurope), negative epoxy photoresist e.g. SU-8 (MicrChem), hydrogensilsesquioxane (HSQ) and poly(aryl ether ketone) (PEEK).

In certain embodiments the flexible substrate comprises a layeredstructure comprising two polymer substrate layers spaced apart from oneanother by an interlayer (e.g. an inorganic layer such as siliconnitride, silicon dioxide or aluminium oxide). In this way, curling ofthe flexible substrate is mitigated or prevented.

In certain embodiments the flexible substrate material comprises one ormore of: a metal oxide, a metal phosphate, a metal sulphate, a metalsulphite, a metal nitride, a metal oxynitride, an inorganic insulatorand a spinnable glass.

In certain embodiments the interface between the carrier and theflexible substrate is formed by direct adhesion of the flexiblesubstrate to the carrier.

In certain embodiments the interface comprises an interlayer.

In certain embodiments the interlayer comprises an adhesive.

In certain embodiments the interlayer comprises titanium metal.

In certain embodiments the interlayer is patterned.

In certain embodiments the process comprises the step of singulating theIC substrate units by releasing each of them from the carrier followingthe completion of the IC formation process thereon.

According to a third aspect, the present invention provides a processfor manufacturing a plurality of discrete integrated circuits (ICs) on acarrier, the process comprising the steps of:

-   -   providing a carrier for a flexible substrate;    -   depositing a pattern of a flexible substrate of uniform        thickness on said carrier, wherein said pattern of said uniform        thickness flexible substrate defines a plurality of IC substrate        areas spaced apart from one another by a plurality of IC        connecting areas;    -   forming an integrated circuit on at least one of the IC        substrate units.

In certain embodiments the process comprises forming integrated circuitson each of the IC substrate units.

In certain embodiments the IC substrate units on the carrier are uniformin shape.

In certain embodiments the IC substrate units are polygonal.

In certain embodiments the IC substrate units are irregular in shape.

In certain embodiments at least one edge of at least one of the ICsubstrate units on the carrier comprises at least one indentation.

In certain embodiments the edge comprises a series of indentations.

In certain embodiments the carrier is rigid.

In certain embodiments the carrier is glass, polycarbonate or quartz.

In certain embodiments the carrier is flexible.

In certain embodiments the carrier is a flexible release tape.

In certain embodiments at least a portion of the flexible substrate isdeposited in a pattern so as to provide the IC connecting areas in theform of channels in a pattern at predetermined location(s) on thecarrier.

In certain embodiments the pattern is formed of a series of intersectingchannels extending between the edges of the carrier.

In certain embodiments the pattern of channels is uniform across thecarrier.

In certain embodiments the pattern of channels is non-uniform across thecarrier.

In certain embodiments the flexible substrate is formed of a singlelayer.

In certain embodiments the flexible substrate material is a polymer.

In certain embodiments the flexible substrate material comprises one ormore of polyimide, polyethylene terephthalate (PET), parylene,benzocyclobutene, Cytop™ (AGC Chemicals Europe), negative epoxyphotoresist e.g. SU-8 (MicrChem), hydrogen silsesquioxane (HSQ) andPolyaryletheretherketone (PEEK)

In certain embodiments the flexible substrate comprises a layeredstructure comprising two polymer substrate layers spaced apart from oneanother by an interlayer (e.g. an inorganic layer such as siliconnitride, silicon dioxide or aluminium oxide).

Unless otherwise stated, the embodiments described in respect of thefirst and second aspects of the invention are embodiments of the thirdaspect of the invention.

According to a further aspect, the present invention provides anapparatus arranged to implement a process in accordance with the presentinvention.

According to a further aspect, the present invention provides a carriercomprising a plurality of discrete ICs formed in accordance with aprocess of the invention.

According to a yet further aspect, the present invention provides acarrier comprising a plurality of discrete ICs wherein at least one ofthe plurality of discrete ICs comprises a first electrical contact pad,at least one second electrical contact pad, and an insulating membercomprising a bridging insulating portion and a laterally extendinginsulator portion extending from the bridging insulating portion. Thus,the first electrical contact pad is electrically isolated from thesecond electrical contact pad, so that each of the first and secondelectrical contact pads can be connected to application circuit trackswhere the end portions are electrically separated from one another.

In certain embodiments the laterally extending insulator portion extendssubstantially from an end of the bridging insulating portion.

In certain embodiments, the insulating member is formed of flexiblesubstrate.

In certain embodiments, the bridging insulating portion electricallyisolates the first electrical contacting element and the secondelectrical contacting element from one another.

In certain embodiments, at least one of the first electrical contact padand the at least one second electrical contact pad is located on thelaterally extending insulator portion.

In certain embodiments, the other of the at least one of the firstelectrical contact pad and the at least second electrical contact pad islocated at an end of the bridging insulating portion remote from thelaterally extending insulator portion. In this way, the first electricalcontact pad and the second electrical contact pad are separated apartfrom each other, allowing the IC to bridge across a greater distance.

In certain embodiments, the insulating member is any one of thefollowing shapes: Z-shape, L-shape, I-shape, C-shape, T-shape orW-shape. Thus, the shape of the IC can be chosen to match the requiredapplication based on the configuration of the application circuittracks, or the arrangement of application circuit contacts, that the ICis applied upon. For example, the application of the IC may beconstrained, for example, by the footprint area of its circuitry or theminimum contact pad separation.

In certain embodiments, the bridging insulating portion has a width lessthan that of the laterally extending insulator portion. Thus, thefootprint of the IC is further reduced, maximising the efficient carrierfootprint coverage during manufacture and maximising the IC costreduction potential.

In certain embodiments, the bridging insulating portion has a uniformwidth.

In certain embodiments, the bridging insulating portion has anon-uniform width.

In certain embodiments, the first electrical contact pad and the atleast second electrical contact pad are each located on the substrate.

In certain embodiments, the laterally extending insulator portionextends from the bridging insulating portion at an angle of 1° to 179°.

In certain embodiments, the laterally extending insulator portionextends substantially perpendicularly from the bridging insulatingportion. In this way, the ICs may be conveniently designed upon, orapplied to circuitry which is designed upon, perpendicular grids. Thesegrids are a common pattern that IC design automation and assembly toolsare designed to produce.

In certain embodiments, the IC comprises a second laterally extendingportion.

In certain embodiments, the electrical circuit comprising the IC iselectrically connected to an application circuit at the first electricalcontact pad and the at least second electrical contact pad of theintegrated circuit.

In certain embodiments, the application circuit comprises: a firstcircuit contact and a second circuit contact.

In certain embodiments, the first circuit contact is adapted toelectrically contact an electrical contact pad of the IC.

In certain embodiments, the second circuit contact is adapted toelectrically contact a second electrical contact pad of the IC.

In certain embodiments, the application circuit further comprises atleast one application circuit feature interposed between the firstcircuit contact and the second circuit contact. In this way, the contactpads of the IC can contact the first and second circuit contacts,allowing the IC to bridge across the at least one application circuitfeature interposed between the first and second circuit contacts andwithout making electrical contact with the at least one applicationcircuit feature.

In certain embodiments, at least one of the first circuit contact andthe second circuit contact is operable to be angled relative to at leastone of the electrical contact pads. In this way, the shape of the IC maybe adapted to contact application circuit tracks which are non-parallelto one another, increasing the range of applications of the IC.

In certain embodiments, an integrated circuit assembly comprises aplurality of the ICs.

In certain embodiments, the carrier comprises a plurality of the ICsarranged in a repeated pattern. In certain embodiments, the pattern is atessellated pattern. Thus, the carrier footprint coverage by the ICs ismaximised, allowing for more efficient use of carrier surface area.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described withreference to the accompanying drawings of which:

FIGS. 1a to 1d show the formation of a plurality of discrete ICs on apatterned substrate on a carrier formed in accordance with an embodimentof the process of the invention;

FIGS. 1e to 1f show the formation of a plurality of discrete ICs on apatterned substrate on a carrier formed in accordance with an embodimentof the process of the invention;

FIG. 2 is a diagrammatic representation of a patterned substrate for aplurality of discrete ICs on a carrier formed in accordance with anembodiment of the process of the invention;

FIG. 3 is a diagrammatic representation of a patterned substrate for aplurality of discrete ICs on a carrier formed in accordance with anembodiment of the process of the invention;

FIGS. 4a to 4c show a plurality of discrete substrate units each havingan IC formed thereon on a carrier and one or more structures in one ormore channels between adjacent substrate units in accordance with anembodiment of the process of the invention;

FIG. 5 shows four discrete substrate units on a carrier spaced apart bytwo intersecting channels, one of the substrate units comprising an edgeprofile;

FIGS. 6a to 6e show various embodiments for the shape of the discretesubstrate units;

FIGS. 7a and 7b show a carrier comprising an IC formed on a discretesubstrate unit;

FIGS. 7c and 7d show a carrier comprising an IC formed on a discretesubstrate unit comprising electrical connections made through the IClayer and the substrate layer onto the carrier in an embodiment of thepresent invention;

FIGS. 8a to 8e show a method for patterning channels in a metal seedinglayer;

and

FIGS. 9a to 9d show an IC applied to different configurations ofapplication circuits.

DETAILED DESCRIPTION

Referring now to FIGS. 1a to 1d this shows the formation of a pluralityof discrete ICs on a patterned substrate on a carrier formed inaccordance with an embodiment of the process of the invention.

As seen in FIGS. 1a and 1b , a flat glass carrier is provided onto whicha layer of polyimide substrate 3 is deposited. The polyimide substratelayer has a uniform thickness across the glass carrier 1. A lithographicprinting technique is used to pattern the polyimide substrate 3 (seeFIG. 1c ) to define a plurality of IC substrate areas 5 spaced apartfrom one another by a plurality of IC connecting areas 7. The ICconnecting areas 7 cross the substrate 3 from edge to edge bothlongitudinally and transversely to form a pattern of intersecting lines7 and a plurality of uniform IC substrate areas 5.

The substrate 3 is then removed by etching, e.g. developing away exposedparts of substrate 3 contained within the IC connecting areas 7,exposing the carrier 1 and forming channels in the flexible substrate 3.The plurality of IC substrate units 5 are spaced apart from one anotheron the carrier 1 by the channels.

As seen in FIG. 1d , layers of an integrated circuit 9 are then formedon each of the IC substrate units 5 to form a plurality of discreteintegrated circuits 9 on the substrate 3 and spaced apart from eachother by channels.

Each discrete IC 9 can then be singulated by removing same and itssubstrate unit 5 from the carrier 1 (not shown).

In a variation of the process (not shown), following deposition andpatterning of the flexible polyimide substrate layer to define aplurality of IC substrate areas spaced apart from one another by ICconnecting areas, a portion of an integrated circuit is formed on eachof the IC substrate areas. Thereafter, the flexible substrate is removedfrom the IC connecting areas by etching the substrate from the carrierto form channels in the flexible substrate and a plurality of discrete,partially formed IC substrate units spaced apart from one another on thecarrier by said channels. Once the channels have been formed in thesubstrate, formation of the integrated circuit on the IC substrate unitsis completed.

As illustrated in FIGS. 1a to 1f , IC substrate units 5 are formed asdiscrete units on carrier 1 prior to completion of the formation of theIC 9 on the substrate unit 5. At one or more stages in IC manufacture,lithographically-defined patterning and subsequent etching removessubstantially all material layers, including the substrate layer 3 lyingoutside the boundaries of each IC substrate unit 5 at that stageexposing the carrier 1 in the channels (see 11 in FIGS. 1e and 1f )between the IC substrate units 5. This may be performed after depositionof the substrate layer 3 onto a carrier 1, in which case the boundariesof each IC 9, and any spaces and/or structures between and within them,are defined in that substrate layer 3. The substrate layer 3 can then bepatterned in this way either in process steps directly followingdeposition of the substrate 3 (FIG. 1a to 1d ), or in any subsequentmaterial removal step that employs a suitable technique, e.g. an etchingtechnique to which the substrate 3 is sensitive. Material subsequentlydeposited on the IC substrate units 5 during the IC manufacturingprocess, e.g. semiconducting, conducting or insulating material, may beremoved from outside the IC substrate unit 5 boundaries and any spacesor structures between or within them, in one or more subsequent etchingsteps. In this way insulating, conducting and semiconducting materiallying outside the IC substrate unit 5 boundaries is removed at anysuitable step in the IC formation process that employs a compatiblematerial patterning and/or removal technique.

More than one layer of material may be removed in any one etching step,so that IC substrate unit boundaries are defined fewer times during themanufacturing process.

It will be understood that measures need to be taken to maintain thesmall distances, i.e. channels, between IC substrate units, inparticular if thick layer(s) of IC material are etched in a single step.By way of example, if etching to remove several μm (e.g. 0.25 μm to 10μm, preferably 0.5 μm to 2 μm) in thickness of polymer material(s)occurs in one step, an oxygen plasma etch may produce IC substrate unitboundaries that are relatively perpendicular to the plane of thesubstrate, in a short time. This may allow a scribe line width of lessthan 10 μm to be achieved. Channels of less than 10 μm width result inless material wastage during the formation of a plurality of discreteICs on a carrier. In certain arrangements, the etching process can beoptimised to be largely anisotropic (predominantly z-axis).

As shown in FIGS. 1e and 1f , an embodiment of the process formanufacturing a plurality of discrete integrated circuits (ICs) on acarrier, comprises providing a glass carrier 1 and printing a pattern ofa discrete flexible polyimide substrate units 5 of uniform thickness onthe glass carrier 1. The pattern of discrete polyimide substrate units 5are spaced apart from one another by a plurality of channels 11 exposingthe glass carrier 1 between the substrate units 5. As shown in FIG. 1f ,integrated circuits 9 are then formed on each of the discrete polyimidesubstrate units 5 by depositing layers comprising devices and/orelectrical interconnection networks to form the IC 9 on the substrateunit 5. In the embodiment depicted in FIGS. 1e and 1f , each polyimidesubstrate unit 5 has an IC 9 formed thereon. In alternative embodiments(not shown), ICs may be formed on some, but not all of the polyimidesubstrate units.

The pattern of discrete flexible polyimide substrate units are formed ofone or more selectively deposited (e.g. by printing) substrate layers,so that initial formation of discrete substrate units 5 on the carrier 1does not require lithographically-defined patterning. In othervariations, other layers of the IC (e.g. conductor, insulator,semiconductor) are selectively deposited onto the substrate units 5 toreduce the number of lithographic patterning steps required to maintainthe substrate units and ICs thereon as discrete units.

FIG. 2 shows an alternative substrate unit formation in which polyimidesubstrate units 50 are formed on a polycarbonate carrier 10. A uniformthickness of substrate 3 is initially deposited on carrier 10 andpatterned by lithographic patterning as shown in FIGS. 1b and 1c . Thediscrete polyimide substrate units 50 are formed by removal (e.g. byetching) of a partial thickness of substrate material 3 from the ICconnecting areas (7 in FIG. 1c ) to form channels 51 in which aninterconnecting portion 53 of polyimide substrate 3 remains betweenadjacent substrate units 50. This could alternatively be achieved by thepositive photoresist process described above but with an under-developafter exposure to ensure that some of the exposed channels remain.

The interconnecting portions 53 of substrate material 3, having athickness “y”, form one or more physical connections between adjacent ICsubstrate units 50. In this way, the first substrate layer 3 ispatterned and etched so that the substrate 3 lying outside the ICsubstrate unit 50 boundaries is thinner than that lying inside theboundaries of the IC substrate units 50. The substrate 53 connectingadjacent IC substrate units in the channels 51 is approximately 100-200nm thick, whereas the IC substrate units are about 5 μm when deposited.This thin connecting material 53 is left in place to improve handling ofthe flexible substrate, e.g. to hold the IC substrate units 50comprising the ICs (not shown) in place, prior to singulation of the ICsubstrate units 50 by removing them from the carrier 10 and integrationof the ICs.

In an alternative embodiment shown in FIG. 3, uniform polyimidesubstrate is deposited on the glass carrier 100. Using lithographicpatterning the polyimide IC substrate areas 500 are defined togetherwith IC connecting areas 70 initially having the same uniform substratethickness as the IC substrate areas 500. Using etching, the entirethickness of polyimide substrate is removed from a series of patches 71to expose the underlying carrier 100. In this way, a series ofperforations are formed in the substrate in the IC connecting areas suchthat the channels 111 a, 111 b comprise sequential areas of substrateand exposed carrier. In this way, the polyimide material lying outsidethe IC substrate unit 500 boundaries is patterned with holes or otherfeatures to form discrete IC substrate units which can be released fromthe carrier 100 to give single IC substrate units comprising an ICthereon (not shown). This pattern could take the form of perforations toensure that the ICs separate when and where intended. Singulation of theICs formed with such partial removal of substrate material connectingadjacent ICs can be achieved at least in part by tearing of thesubstrate material in the channels 111 a, 111 b. The substrate in the ICconnecting areas 70 surrounding the patches 71 may be the same thicknessas the substrate in the IC substrate areas 500. Alternatively a partialthickness of the substrate in the IC connecting areas 70 may be removed,e.g. by etching, as described above in reference to FIG. 2.

When lithography is used to pattern the substrate, smaller distancesbetween IC boundaries (i.e. channels) can be defined than is possiblewith conventional wafer dicing techniques. Channel line widths can bebelow 10 μm, reducing substrate waste and increasing the number of ICswhich can be formed on one common substrate on a carrier. For example,channels 11, 51 may have widths of between 0.1 μm and 20 μm, between 0.5μm and 15 μm, or between 5 μm and 10 μm.

In addition, the processes of the present invention are faster andcleaner than conventional wafer formation and dicing methods.

As shown in FIGS. 4a to 4c , the IC connecting area can itself bepatterned to include test structures 271, 371, 471 (e.g. fiducials foralignment of masks) or other features (e.g. resistors, capacitors,transistors, or combinations of these, or circuits, e.g. ringoscillators). Thus, when the etching step removes substrate materialfrom the IC connecting areas to form channels 211 a, 211 b, 311 a, 311 band 411 a, 411 b, between IC substrate units comprising ICs thereon(559, 359, 459) the test structures or other features remain within thechannels between the IC substrate units. Such test structures and otherfeatures may subsequently be singulated or they may be left on thecarrier when the ICs are removed from the carrier.

The test structures 271, 371, 471 or other features may be locatedbetween rectangular IC substrate unit 559 corners (FIG. 4a ) or betweencorners of IC substrate units that are shaped to accommodate them withminimal loss in IC surface area in the IC formed on the IC substrateunit 359, 459 (FIGS. 4b, 4c ).

In further embodiments (not shown), features (e.g. resistors,capacitors, transistors, or combinations of these, or circuits, e.g.ring oscillators) between IC substrate units upon which ICs are formedcan be formed on the substrate or on a layer beneath the substrate, forexample on an insulating layer or on the glass carrier itself.

ICs and the substrate units on which they are formed may have boundarygeometry (i.e. edges) that is not rectangular. As shown in FIG. 5, theboundary of the IC and the IC substrate unit on which it is formed 659can be profiled with indentation (recesses) 603. The profiled edge maybe unique to the substrate units 659 on a single carrier 601 or may beshared within a batch of carriers carrying IC substrate units with ashared edge profile. In this way, the edge (boundary) profiling can beused as a unique identifying feature for a carrier or a batch ofcarriers.

Referring to FIGS. 6a, 6b, 6c, 6d and 6e , the shape of the IC substrateunits 5, 50, 500, 559, 359, 459, 659 and the ICs formed thereon can bemade to match any application requirements. As best seen in FIGS. 6c and6d , the IC and IC substrate unit 759 (FIG. 6c ) and 859 (FIG. 6d ) isshaped such that two or more of its electrical contacts make contact toapplication circuit contacts 704 a, 704 b and 804 a, 804 b respectivelythat are widely separated. The wide separation of application circuitcontacts 704 a, 704 b and 804 a, 804 b respectively can be accommodatedwith a minimum IC surface area.

As shown in FIG. 6a , any tessellating shape may be used to retainefficient use of substrate area. In this way, there is minimum substratewastage when the IC substrate units are made discrete on the carrier byforming channels between adjacent substrate units. Straight-sidedgeometries of IC substrate units include regular or irregulartriangular, pentagonal, hexagonal, square, rectangular and so on.

As best seen in FIG. 6b , the edges of the IC substrate units and theICs formed thereon can be curved, concave or convex. In accordance withthe embodiment shown in FIG. 5, the edges (boundaries) of the ICsubstrate units and the ICs formed thereon can incorporate security ortraceability features, such as coded edge profiles. By utilising anirregular or non-conventional shape of IC substrate unit and IC formedthereon 959 a-i (FIG. 6a ) and 959 j-r (FIG. 6b ) an additional andeasily recognisable security and traceability characteristic isprovided.

FIG. 6e shows additional straight-sided non-rectangular shapes of ICsubstrate units and the ICs formed thereon, including a Z-shape 959 s,L-shape 959 t, I-shape 959 u and C-shape 959 v. The shape of the ICsubstrate units and the ICs formed thereon 959 s-v can be made to matchany application circuit connection requirements. It is envisaged thatthe IC substrate units and the ICs formed thereon may also take the formof alternative straight-sided shapes such as a W-shape, T-shape, or anyother arbitrary shape to fit the requirements of the application circuitsuch as, but not limited to, the configurational layout of theapplication circuit.

Referring now to FIGS. 9a, 9b, 9c and 9d , the IC substrate units andthe ICs formed thereon 959 s-v of FIG. 6e are selected to fit differentconfigurations of application circuits 1272. The ICs 959 s-v are shapedsuch that two or more of its electrical contact pads 1262 make contactto application circuit 1272 contacts that are widely separated. Becausethe IC 959 s-v is shaped to be non-rectangular as described, theelectrical contact pads 1262 make contact to application circuit 1272contacts where the application circuit 1272 is orientated in anarbitrary or non-conventional way, such as where the applicationcircuits 1272 are: non-parallel to one another (FIGS. 9c and 9d ),non-adjacent to one another (FIGS. 9a-9d ), of different lengths and/orwidths (FIGS. 9a-9c ), separated from one another by additionalapplication circuits (FIGS. 9a-9c ) and/or obstructed by an applicationcircuit obstruction 1500 (FIG. 9d ). Such shapes of ICs 959 s-v removedesign constraints on application circuits 1272, facilitating newapplications, and reduce the size of the IC footprint compared to arectangular shaped IC required to connect to the equivalent applicationcircuit 1272. In this way, each IC uses less carrier area, allowing moreICs to be produced per carrier. Thus, manufacturing costs are reduced,as are the costs of the IC itself. The shaped IC 959 s-v can bedimensioned for efficient carrier footprint coverage during manufacture,maximising the IC cost reduction potential. An example of this is toprovide a tessellated pattern of IC shapes to provide a high packingdensity on a carrier. The tessellations themselves may be optimised forpacking density and/or the ease of removal from the carrier.

FIG. 9a shows an I-shaped IC 959 u comprising an insulating bridgingportion 1252 having a first laterally extending section 1254 at one endand a second laterally extending section 1256 at the other end. Thefirst and second sections 1252, 1254 each comprise a contact pad 1262.The contact pads 1262 are electrically isolated by an insulatingbridging portion 1252 of the body portion. The first section 1254extends laterally from both sides of the bridging insulating portion1252. The second section 1256 likewise extends laterally from both sidesof the bridging insulating portion 1252. The two contact pads 1262 arein electrical contact with two application circuit 1272 tracks (e.g. endportions). Two interposing application circuit tracks are positionedbetween the application circuit 1272 tracks contacting the contact pads1262. The IC 959 u forms a bridge to electrically connect theapplication circuit 1272 tracks (e.g. end portions) via contacting thecontact pads 1262, allowing application circuits that cannot be placedimmediately adjacent to each other to be connected. In this example, theIC 959 u has two contact pads 1262, one contact pad 1262 situated ateach end of the body portion, on the first 1254 and second sections 1256to contact application circuit tracks that are separated by twointerposing application circuit tracks, but it should be appreciatedthat an IC can have more than two contact pads 1262 that areelectrically isolated from one another, and can bridge any number ofinterposing application circuit tracks according to the presentdisclosure. In this example, the insulating bridging portion 1252 has awidth that is less than the width of the other parts of the bodyportion, i.e. first and second sections 1254 and 1256, to reduce the ICfootprint and to save cost. The bridging insulating portion 1252 in thisexample has a uniform shape, however the bridging insulating portion1252 may also be a non-uniform shape according to the presentdisclosure, such as where the bridging insulating portion 1252 has anhourglass shape.

FIG. 9b shows a Z-shaped IC 959 s comprising a body portion having afirst section 1254 on one end and a second section 1256 and the otherend, the first and second sections each locating a contact pad 1262. Thecontact pads 1262 are electrically isolated by an insulating bridgingportion 1252 of the body portion. The first section 1254 extendslaterally from one side of the bridging insulating portion 1252 and thesecond section 1256 extends laterally from the other side of thebridging insulating portion 1252, so as to form a Z-shaped IC 959 s. Thetwo contact pads 1262 are in contact with two application circuit 1272tracks. Two interposing application circuit tracks are positionedbetween the application circuit 1272 tracks contacting the contact pads1262. The IC 959 s forms a bridge to electrically connect theapplication circuit 1272 tracks via contacting the contact pads 1262,allowing application circuits that cannot be placed immediately adjacentto each other to be connected. The Z-shaped IC 959 s is placed on anapplication circuit 1272 in an alignment that is rotated to furtherreduce the size of the IC, whilst allowing the contacts to be placed asfar away from each other as possible. The application circuit 1272tracks have a width and separation. Given that constraint, and the needto squeeze as many ICs onto a wafer as possible, this is particularlyadvantageous.

FIG. 9c shows a L-shaped IC 959 t comprising a body portion having afirst section 1254 extending laterally from an end of a bridginginsulating portion 1252. The L-shaped IC 959 t in this example has fourcontact pads 1262. Two contact pads 1262 are located on the firstsection 1254, a third contact pad 1262 is located at a junction of thebridging insulating portion 1252 and the first section 1254, and thefourth contact pad is located on an end of the bridging insulatingportion 1252 opposite the junction of the bridging insulating portion1252 and the first section 1254. By shaping the IC as a L-shaped IC 959t, the size of the IC footprint compared to a rectangular shaped IC 1274required to connect to the equivalent application circuit 1272 isreduced, allowing more ICs to be produced per wafer. The L-shaped IC 959t serves as a reduced-footprint bridge for four application circuit 1272tracks.

FIG. 9d shows an alternative L-shaped IC 959 t to the one in FIG. 9c ,having a shorter bridging insulating portion 1252 (in this particularexample, bridging is understood to “bridge” between application circuittracks 1272 or contacts, whether or not there are application circuitfeatures, i.e. tracks, components, obstructions, provided between thosecontacts). The four contact pads 1262 on the IC 959 t contact fourdifferent application circuit tracks 1272. Two contact pads 1262 arelocated on the first section 1254, a third contact pad 1262 is locatedat a junction of the bridging insulating portion 1252 and the firstsection 1254, and the fourth contact pad is located on an end of thebridging insulating portion 1252 opposite the junction of the bridginginsulating portion 1252 and the first section 1254. The footprint of theL-shaped IC is smaller compared to the equivalent rectangular shaped IC1274 required to bridge the equivalent application circuit. The L-shapeof the IC allows the IC to avoid contact with an application circuitobstruction 1500, so as to remove design constraints on applicationcircuits having such obstructions 1500, which make the equivalentrectangular shaped IC 1274 impractical or compromising to other aspectsof application circuit design. In this example, the application circuitdesign constraint is an application circuit obstruction 1500, however itis appreciated that another IC or an electronic component, a display oran edge of the application circuit substrate may also, or alternatively,be design constraints that are overcome by the shaped IC. The shaped ICscan be arranged in a tessellated pattern on the carrier so that thenumber of ICs produced on a single carrier is maximised for efficientcarrier coverage during manufacture, maximising the IC cost reductionpotential.

In the examples described in FIGS. 9a to 9d , the insulating bridgeportion 1252 and the other parts of the IC body portion, i.e. first andsecond sections 1254 and 1256, form an angle of 90° but it should beappreciated that other angles may be formed, such as an angle more than0° and less than 180°.

In all examples integrated circuits ICs may be positioned in any one ormore of the bridging portion(s) 1252 and the first and second sections1254 and 1256, and the ICs may connect electrically to contact pads1262.

Such shaped ICs may be manufactured by the methods of substratepatterning described herein. Alternatively, the shaped ICs may beproduced using any conventional method of manufacture and thensingulated, either on the carrier or on a flexible support (e.g. a UVrelease ‘wafer frame’), by methods such as laser dicing or mechanicalcutting/dicing (e.g. ‘cookie cutter’ stamping).

FIGS. 7a and 7b each show an IC 1059, 1059′ formed on a substrate (notshown) and comprising internal boundaries in the form of apertures 1003,1003′, from which apertures substrate material is removed during etchingsteps. The apertures 1003, 1003′ form one or more through-holes in theIC 1059, 1059′ and the underlying substrate to expose the glass carrier1001, 1001′. The apertures may be singular in each IC or may bepatterned in each IC and may be for functional or aesthetic purposes.FIG. 7c shows four such through-holes 1003, 1003′ which, in the depictedembodiment, allow adhesive 1005, 1005′ to flow through the IC 1059between its upper face 1007 in which it contacts electrical connections1015, 1015′ and its lower face 1009, through the flexible IC substrateunit 1011 and into contact with electrical connections 1013, 1013′embedded in the glass carrier 1001. In this way, the IC 1059 can beattached to an application circuit or other surface. For example,following formation of the IC 1059, the flexible IC substrate unit 1011and IC 1059 may be removed from the glass carrier 1001 and placed uponan application circuit such that the through-holes 1003 and/or 1003′ arealigned with electrical connections embedded in the application circuit.Conductive adhesive 1005 and/or 1005′ may then be applied near to theupper ends of through-holes 1003 and/or 1003′ to flow through the IC1059 between its upper face 1007 in which it contacts electricalconnections 1015, 1015′ and its lower face 1009, through the flexible ICsubstrate unit 1011 and into contact with electrical connections 1013,1013′ embedded in the application circuit beneath. Such attachmentprovides a convenient way to connect electrical connections on the upperface of the IC to electrical connections in an application circuitwithout inverting the IC.

In the embodiment of FIG. 7d , a conducting adhesive 1005 inthrough-hole 1003 allows electrical connections to be made between anelectrical contact 1015 on the upper face 1007 of the IC 1059 and anelectrical contact 1013 on the lower face of the IC substrate unit 1011.The conductive adhesive is located to make further electrical connectionwith electrical contacts on the surface to which the IC is attached oncarrier 1001. In the embodiment shown, electrical contact 1013 isembedded in IC substrate unit 1011 and the glass carrier 1001 comprisesa groove 1021 into which the adhesive flows. Similarly to the aboveexample, the IC 1059 can be attached in this way to an applicationcircuit or other surface instead of to the glass carrier 1001, so thatelectrical contacts 1015 (on the upper face 1007 of the IC 1059) and1013 (on the lower face of the IC substrate unit 1011) are connectedwith each other and with further electrical connections via a groove inthe application circuit or other surface.

As previously described in the embodiment illustrated in FIGS. 1a-1f ,IC substrate units 5 are formed as discrete units on carrier 1 prior tocompletion of the formation of the IC 9 on the substrate unit. In thisembodiment, a lithographic printing technique is used to pattern thepolyimide substrate 3 to define a plurality of IC substrate areas 5spaced apart from one another by a plurality of IC connecting areas 7.The substrate 3 is then removed by etching to expose the carrier 1 andform channels 11 in the substrate 3. The plurality of IC substrate units5 are spaced apart from one another on the carrier 1 by the channels 11.Layers of an integrated circuit 9 are formed on each of the IC substrateunits 5 to form a plurality of discrete integrated circuits 9 on thesubstrate 3 and spaced apart from each other by the channels 11. Eachdiscrete IC 9 can then be singulated.

As such, measures need to be taken to maintain the small distances, i.e.channels 11, between IC substrate units 5, in particular if thicklayer(s) of IC material are etched in a single step.

In certain embodiments, following the initial patterning of the ICsubstrate units 5, the channels 11 between IC substrate unit boundariesare filled with a material that may be easily removed at the ICsingulation stage. This approach is applicable to processes in which thechannels 11 between IC substrate units 5 are formed when the flexiblesubstrate is completely removed, and also to processes in which theflexible substrate is only partially removed to form channels 11, suchas when flexible substrate material connecting adjacent IC substrateunits 5 is left behind, as previously described and illustrated in FIG.2. The channels 11 are filled completely, i.e. to the level of the uppersurface of the substrate units 5, such that the substrate 3 and channels11 are substantially co-planar. In this way, subsequent processingduring IC manufacture is improved. Once the ICs are completed, thematerial used to fill the channels 11 and the layers deposited on top ofthem may be removed by chemical processing, e.g. wet or dry etching.Three examples of this alternative approach are described herein.

In a first example, after the substrate units 5 have been patterned anddefined by etching or selective deposition of substrate, the channels 11between the IC substrate units 5 are filled by nickel electrolessplating. In this example, the channels 11 are filled by nickel, howeverit should be appreciated that alternative materials can fill thechannels, such as but not limited to copper, silver gold, palladium orother alternatives. This enables the wafer to be substantiallyplanarized, so that any damaging effects arising in subsequentdeposition and etching steps in IC manufacture are reduced, oreliminated entirely. Once IC manufacturing is complete, the ICs may besingulated on the carrier 1 using a wet etching, dry etching or otherappropriate chemical process, to selectively remove the metal channelfillings and the layers deposited onto them. In this example an etchantcan be used to etch the nickel electroless plating, however it shall beappreciated that etchants can be used, such for other materials, orselective etchants that etch certain materials and not others, such asselective etchants for copper and nickel that would not etch aluminium.In this way, the bottom of the channel 11 would be cleared, provided theaspect ratio of the channel 11 is not too high, and the channel 11 isnot too narrow.

In another example, the channels 11 between patterned IC substrate units5 are filled with a polymer that differs from the polymer used to formthe substrate units 5. For example, if the substrate units 5 are formedfrom polyethylene naphtholate (NAP) or polyimide (PI), then the channels11 may be filled with a different polymer such as polymethylmethacrylate (PMMA) or polyvinyl acetate (PVA). It should be appreciatedthat further combinations of materials can be used according to thepresent disclosure. Once ICs are formed on the IC substrate units 5,they may be singulated using a wet etching, dry etching or otherappropriate chemical process, to selectively remove the channel-fillingpolymer. Depending on the processes used to form ICs on the IC substrateunits 5, it may be necessary to protect the channel-filling polymer witha capping layer (not shown) to prevent its removal during IC formation.Any such capping layer, if required, may be patterned to align with onlythe channels 11 between substrate units 5, or may additionallysubstantially cover the upper surfaces of the substrate units 5. Thecapping layer may be removed from the channel-filling polymer at anappropriate point prior to singulation.

In a further example, the channels 11 are patterned on the carrier 1 ina metal seeding layer, for example, a copper seeding layer (not shown).In this example, the channels 11 are patterned on the carrier 1 in ametal seeding layer, but it should be appreciated that other metals canbe used according to the present disclosure. This step can occur eitherprior to, or after the substrate 3 is deposited onto the carrier 1 andoccurs using a patterning deposition technique such as, but not limitedto, lithography, sputtering or any other appropriate technique. Thesubstrate 3 is then deposited, if not done previously, and patternformed between the channels 11 so that the channels 11 are etched in asubstrate layer deposited over the metal seeding layer. In this example,the channels 11 are etched in a substrate layer deposited over the metalseeding layer, but the substrate 3 can alternatively be selectivedeposited between the metal seeding layer channels. After the ICsubstrate units 5 have been patterned on the carrier, a thicker layer ofmetal is grown on the metal seeding layer to fill the channels 11between the IC substrate units 5. This is performed by a chemical vapourdeposition technique, or an alternative technique such as, but notlimited to, physical vapour deposition, electroplating or electrolessplating.

FIGS. 8a to 8e illustrate an alternative to the above techniques forpatterning channels and filling them with metal by instead formingbottom-side contacts or through-chip vertical interconnect accesses(vias). In this alternative, the initial patterning of a metal layer ormetal seeding layer 1181 includes internal features within theboundaries of subsequently formed IC substrate units. Metal seeding ormetal layer deposition could alternatively be performed after thesubstrate units and their internal features have been formed. In thisexample, only the internal features, and not the channel features, areshown for clarity. Once the substrate 1103 and metal or metal seedinglayers 1181 have been patterned and the internal features have beencleared of any substrate material, a thicker layer of metal 1183 isgrown or deposited on the metal or seeding layer 1181 to substantiallyfill these features (i.e. the channel features or the internal features)up to the upper surface of the substrate units. During the subsequentprocess of IC 1109 formation, wiring (not shown), in the form of metaltracks, for the IC may be connected to the metal 1183 deposited onto theinternal features. After this (and additional deposition of furtherlayers, singulation and separation from the carrier 1101, if required,)has been completed, the internal features form “bottom-side contacts” onthe underside of the IC.

Referring to FIG. 8a , a metal or metal seeding layer 1181 is patternedand forms internal features. The substrate layer 1103 is then depositedand is patterned and removed from above the metal or seeding layer 1181,as shown in FIG. 8b . Subsequently, a thicker layer of metal 1183 isdeposited or grown on top of the metal seeding layer 1181 in order tosubstantially fill the internal features up to the upper surface of thesubstrate 1103, as shown in FIG. 8c . Referring now to FIG. 8d , theintegrated circuit 1109 is formed on top of the substrate 1103 and metallayer 1183 surface. This provides electrical connections between the IC1109 and the metal internal features 1181. Though not shown, the padsare connected to application circuits, such as antennas, and can be doneso without requiring the IC 1109 to be inverted, which simplifies thewhole assembly process.

As seen in FIG. 8e , one or more further layers of metal 1193 can bebuilt on top of the internal features 1181. By doing this, it ispossible to produce “through-chip vias”, which are conductive featuresrunning between the upper surface of the IC 1109 and the wer surface ofthe IC 1109. This allows for “stacking” of ICs 1109 and/or othercomponents in the same physical area, or overlapping areas, on anapplication circuit and which saves area and reduces metal tracking ofinterconnects and reduces cost of the application circuit. It alsoeliminates the need for “crossovers” in metal tracking on theapplication circuit, which reduces the number of required fabricationsteps. Pads can be manufactured in two different ways—either the metalfirst, as described above, or the substrate first.

For the metal-first approach, metal contact pads 1181 are deposited andpatterned directly on the glass carrier 1101 before spin-coating asubstrate 1103. Vias, which may be smaller than or equal to the contactpads in area, are then etched through the film using an appropriateprocess, such as oxygen plasma dry etching for polyimide substrates, andconnections are made to the upper IC layers 1109. These connections1183, 1193 are made with an upper metal layer that routes overpositively sloped sidewalls around the etched vias to form connections,or by methods to fill the vias, such as electro/electroless platingtechniques. In this particular example, the vias in the substrateconnecting to the bottom pad may consist of a limited area, with the pad1181 extending beyond them.

Alternatively, in adopting a substrate-first approach, the substrate1103 is deposited on the glass carrier, and the vias are etched withpositive sidewalls. A metal 1183 is then deposited, so that no breakagesoccur at the via edges. The metal 1183 is routed down to contact theglass carrier 1101 and up to the top of the substrate, and ultimately tothe upper surface of the IC 1109. The bottom pad area is defined in thismethod by the size of the via, so it is preferred that the substrate hasrelatively large etched regions.

To ensure proper release of the metal contact pad areas from thecarrier, a release layer is provided underneath the metal pad, and isdesigned to interact with a laser used for release and results incomplete release of the metal pad area. In this example, the metal padcomprises aluminium and the release layer comprises titanium, but it isenvisaged that alternative materials can be used according to thepresent disclosure.

In embodiments the pattern of the internal boundaries in the ICsubstrate unit and the IC formed thereon may form further securityand/or traceability features.

The discrete IC substrate units and ICs formed thereon are singulated byreleasing them from the carrier. The release process may be an infraredelectromagnetic radiation release process, a heat release or amechanical peel release process.

The discrete IC substrate units and ICs formed thereon on a carrier canbe released from the carrier individually or linked to one or moreadjacent discrete IC substrate units and ICs formed thereon.

Below, there is provided a non-exhaustive list of non-limiting clauses.Any one or more of the features of these examples may be combined withany one or more features of another clause, embodiment or aspectdescribed herein.

Aspects:

-   1. A process for manufacturing a plurality of discrete integrated    circuits (ICs) on a carrier, the process comprising the steps of:    -   providing a carrier for a flexible substrate;    -   depositing a flexible substrate of uniform thickness on said        carrier;    -   patterning said uniform thickness flexible substrate to define a        plurality of IC substrate areas spaced apart from one another by        a plurality of IC connecting areas;    -   removing at least a portion of the thickness of the flexible        substrate from at least a portion of the IC connecting areas to        form channels in the flexible substrate and a plurality of IC        substrate units spaced apart from one another on the carrier by        said channels;    -   forming an integrated circuit on at least one of the IC        substrate units.-   2. A process for manufacturing a plurality of discrete integrated    circuits (ICs) on a carrier, the process comprising the steps of:    -   providing a carrier for a flexible substrate;    -   depositing a flexible substrate of uniform thickness on said        carrier;    -   patterning said uniform thickness flexible substrate to define a        plurality of IC substrate areas spaced apart from one another by        IC connecting areas;    -   forming a portion of an integrated circuit on at least one of        the IC substrate areas;    -   removing at least a portion of the thickness of the flexible        substrate from at least a portion of the IC connecting areas to        form channels in the flexible substrate and a plurality of IC        substrate units spaced apart from one another on the carrier by        said channels; and    -   completing the formation of the integrated circuit on the at        least one of the IC substrate areas.-   3. A process according to aspect 1 or aspect 2, comprising forming    integrated circuits on each of the IC substrate units.-   4. A process according to any one of aspects 1 to 3, wherein each IC    substrate unit comprises flexible substrate of uniform thickness.-   5. A process according to any one of aspects 1 to 4, comprising the    step of: removing the entire thickness of the flexible substrate    from all of each of the IC connecting areas so as to form a    plurality of substrate-free channels on the carrier between each of    the IC substrate units on the carrier.-   6. A process according to any one of aspects 1 to 4, comprising    removing the entire thickness of the flexible substrate from a    portion of each of the IC connecting areas so as to form a plurality    of patterned channels on the carrier wherein at least one channel is    formed between each of the IC substrate units.-   7. A process according to any one of aspects 1 to 4, comprising    removing a first portion of the thickness of the flexible substrate    from a first portion of each of the IC connecting areas and removing    a second portion of the thickness of the flexible substrate from a    second, different portion of each of the IC connecting areas,    wherein the first portion is of greater thickness than the second    portion.-   8. A process according to aspect 6 or aspect 7, comprising forming    perforation lines between adjacent IC substrate units in the IC    connecting areas by sequentially removing and leaving the entire    thickness of the flexible substrate along each of the IC connecting    areas so as to form a plurality of patterned channels on the carrier    wherein at least one channel is formed between each of the IC    substrate units.-   9. A process according to aspect 6 or aspect 7, comprising forming    perforation lines between adjacent IC substrate units in the IC    connecting areas by sequentially removing a first portion of the    thickness of the flexible substrate from a first portion of each of    the IC connecting areas and removing a second portion of the    thickness of the flexible substrate from a second, different portion    of each of the IC connecting areas, wherein the first portion is of    greater thickness than the second portion.-   10. A process according to aspect 6 or aspect 7, comprising forming    perforation lines between adjacent IC substrate units in the IC    connecting areas by sequentially removing the entire thickness of    the flexible substrate and a partial thickness of the flexible    substrate along each of the IC connecting areas so as to form a    plurality of patterned channels on the carrier wherein at least one    channel is formed between each of the IC substrate units.-   11. A process according to any one of aspects 1 to 4 and aspect 6,    comprising forming at least one structure in the IC connecting areas    by removing the entire thickness of the flexible substrate from a    portion of each of the IC connecting areas so as to form a channel    having at least one structure of flexible substrate in the channel,    the structure being spaced apart from the IC substrate units    adjacent to the channel.-   12. A process according to aspect 11, wherein the structure is a    test structure.-   13. A process according to any one of the preceding aspects, wherein    the IC substrate units on the carrier are uniform in shape.-   14. A process according to aspect 14, wherein the IC substrate units    are polygonal.-   15. A process according to any one of aspects 1 to 13, wherein the    IC substrate units are irregular in shape.-   16. A process according to any one of the preceding aspects, wherein    at least one edge of at least one of the IC substrate units on the    carrier comprises at least one indentation.-   17. A process according to aspect 16, wherein the edge comprises a    series of indentations.-   18. A process according to any one of the preceding aspects, wherein    the carrier is rigid.-   19. A process according to aspect 18, wherein the carrier is glass,    polycarbonate or quartz.-   20. A process according to any one of aspects 1 to 18, wherein the    carrier is flexible.-   21. A process according to aspect 20, wherein the carrier is a    flexible release tape.-   22. A process according to any one of the preceding aspects, wherein    at least a portion of the flexible substrate is removed from the IC    connecting areas to form channels in a pattern at predetermined    location(s) on the carrier.-   23. A process according to aspect 22, wherein the pattern is formed    of a series of intersecting channels extending between the edges of    the carrier.-   24. A process according to aspect 22 or aspect 23, wherein the    pattern of channels is uniform across the carrier.-   25. A process according to aspect 22 or aspect 23, wherein the    pattern of channels is non-uniform across the carrier.-   26. A process according to any one of the preceding aspects, wherein    the flexible substrate is formed of a single layer.-   27. A process according to any one of the preceding aspects, wherein    the flexible substrate material is a polymer.-   28. A process according to any one of aspects 1 to 26, wherein the    flexible substrate material comprises one or more of polyimide,    polyethylene terephthalate (PET), parylene, benzocyclobutene,    Cytop™, negative epoxy photoresist, hydrogen silsesquioxane (HSQ)    and Polyaryletheretherketone (PEEK)-   29. A process according to any one of aspects 1 to 25, wherein the    flexible substrate comprises a layered structure comprising two    polymer substrate layers spaced apart from one another by an    interlayer.-   30. A process according to any one of aspects 1 to 26, wherein the    flexible substrate material comprises one or more of: a metal oxide,    a metal phosphate, a metal sulphates, a metal sulphite, a metal    nitride, a metal oxynitride, an inorganic insulator and a spinnable    glass.-   31. A process according to any one of the preceding aspects, wherein    the interface between the carrier and the flexible substrate is    formed by direct adhesion of the flexible substrate to the carrier.-   32. A process according to any one of aspects 1 to 30, wherein the    interface comprises an interlayer.-   33. A process according to aspect 32, wherein the interlayer    comprises an adhesive.-   34. A process according to aspect 32 or aspect 33, wherein the    interlayer comprises titanium metal.-   35. A process according to any one of aspects 32 to 34, wherein the    interlayer is patterned.-   36. A process according to any one of the preceding aspects,    comprising the step of singulating the IC substrate units by    releasing each of them from the carrier following the completion of    the IC formation process thereon.

Throughout the description and claims of this specification, the words“comprise” and “contain” and variations of them mean “including but notlimited to”, and they are not intended to (and do not) exclude othermoieties, additives, components, integers or steps. Throughout thedescription and claims of this specification, the singular encompassesthe plural unless the context otherwise requires. In particular, wherethe indefinite article is used, the specification is to be understood ascontemplating plurality as well as singularity, unless the contextrequires otherwise.

Features, integers, characteristics, compounds, chemical moieties orgroups described in conjunction with a particular aspect, embodiment orexample of the invention are to be understood to be applicable to anyother aspect, embodiment or example described herein unless incompatibletherewith. All of the features disclosed in this specification(including any accompanying claims, abstract and drawings), and/or allof the steps of any method or process so disclosed, may be combined inany combination, except combinations where at least some of suchfeatures and/or steps are mutually exclusive. The invention is notrestricted to the details of any foregoing embodiments. The inventionextends to any novel one, or any novel combination, of the featuresdisclosed in this specification (including any accompanying claims,abstract and drawings), or to any novel one, or any novel combination,of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which arefiled concurrently with or previous to this specification in connectionwith this application and which are open to public inspection with thisspecification, and the contents of all such papers and documents areincorporated herein by reference.

The invention claimed is:
 1. A process for manufacturing a plurality ofdiscrete integrated circuits (ICs) on a carrier, the process comprising:providing a carrier for a flexible substrate; depositing a flexiblesubstrate of uniform thickness on said carrier; patterning said uniformthickness flexible substrate to define a plurality of IC substrate areasspaced apart from one another by a plurality of IC connecting areas;removing at least a portion of the thickness of the flexible substratefrom at least a portion of the IC connecting areas to form channels inthe flexible substrate and a plurality of IC substrate units spacedapart from one another on the carrier by said channels prior to a stepof forming an integrated circuit on at least one of the IC substrateunits; and removing a first portion of the thickness of the flexiblesubstrate from a first portion of each of the IC connecting areas andremoving a second portion of the thickness of the flexible substratefrom a second, different portion of each of the IC connecting areas,wherein the first portion is of greater thickness than the secondportion.
 2. The process according to claim 1, further comprising formingintegrated circuits on each of the IC substrate units.
 3. The processaccording to claim 1, wherein each IC substrate unit comprises flexiblesubstrate of uniform thickness.
 4. The process according to claim 1,further comprising removing the entire thickness of the flexiblesubstrate from all of each of the IC connecting areas so as to form aplurality of substrate-free channels on the carrier between each of theIC substrate units on the carrier.
 5. The process according to claim 1,further comprising removing the entire thickness of the flexiblesubstrate from a portion of each of the IC connecting areas so as toform a plurality of patterned channels on the carrier wherein at leastone channel is formed between each of the IC substrate units.
 6. Theprocess according to claim 5, comprising forming perforation linesbetween adjacent IC substrate units in the IC connecting areas bysequentially removing and leaving the entire thickness of the flexiblesubstrate along each of the IC connecting areas so as to form aplurality of patterned channels on the carrier wherein at least onechannel is formed between each of the IC substrate units.
 7. The processaccording to claim 5, comprising forming perforation lines betweenadjacent IC substrate units in the IC connecting areas by sequentiallyremoving a first portion of the thickness of the flexible substrate froma first portion of each of the IC connecting areas and removing a secondportion of the thickness of the flexible substrate from a second,different portion of each of the IC connecting areas, wherein the firstportion is of greater thickness than the second portion, or comprisingforming perforation lines between adjacent IC substrate units in the ICconnecting areas by sequentially removing the entire thickness of theflexible substrate and a partial thickness of the flexible substratealong each of the IC connecting areas so as to form a plurality ofpatterned channels on the carrier wherein at least one channel is formedbetween each of the IC substrate units.
 8. The process according toclaim 1, further comprising forming at least one structure in the ICconnecting areas by removing the entire thickness of the flexiblesubstrate from a portion of each of the IC connecting areas so as toform a channel having at least one structure of flexible substrate inthe channel, the structure being spaced apart from the IC substrateunits adjacent to the channel.
 9. The process according to claim 1,wherein the IC substrate units on the carrier are uniform in shape. 10.The process according to claim 1, wherein at least one edge of at leastone of the IC substrate units on the carrier comprises at least oneindentation.
 11. The process according to claim 1, wherein the carrieris rigid.
 12. The process according to claim 1, wherein the carrier isflexible.
 13. The process according to claim 1, wherein at least aportion of the flexible substrate is removed from the IC connectingareas to form channels in a pattern at predetermined location(s) on thecarrier.
 14. The process according to claim 1, wherein the flexiblesubstrate is formed of a single layer, or wherein the flexible substratecomprises a layered structure comprising two polymer substrate layersspaced apart from one another by an interlayer.
 15. The processaccording to claim 1, wherein the flexible substrate material comprisesa polymer or one or more of polyimide, polyethylene terephthalate (PET),parylene, benzocyclobutene, Cytop™, negative epoxy photoresist, hydrogensilsesquioxane (HSQ) and Polyaryletheretherketone (PEEK), or one or moreof: a metal oxide, a metal phosphate, a metal sulphates, a metalsulphite, a metal nitride, a metal oxynitride, an inorganic insulatorand a spinnable glass.
 16. The process according to claim 1, wherein aninterface between the carrier and the flexible substrate is formed bydirect adhesion of the flexible substrate to the carrier.
 17. Theprocess according to claim 1, wherein an interface between the carrierand the flexible substrate comprises an interlayer.
 18. The processaccording to claim 1, comprising the step of singulating the ICsubstrate units by releasing each of them from the carrier following thecompletion of the IC formation process thereon.